The automotive industry uses both micro- and macro-machined parts in metal and plastic. This means inspection lines encounter many different types of components and assemblies. Components include valves, gears, stabilizing bars, sensors, and a host of others that go into assembly of the vehicle. The automotive industry is extremely cost-driven, due to constantly changing market preferences. However, it is even more quality-driven. The best way to avoid the high cost of recalls is to catch failures before they occur.

The assembly process for automotive parts involves both inspection for defects and verification of measurements. Inspectors working with micro-machined parts must also be able to detect miniscule variations in measurements that would be within tolerance in a larger part. Operators also encounter macro-machined parts, including parts with curved holes and surfaces. In addition to typical inspection needs – identifying irregularities, pits, and burrs on surfaces – inspectors must also be able to identify errors in curvature and angle.

To handle the wide variety of parts in the automobile assembly process, visual inspection tools must have a wide magnification range. They should be able to focus on an extremely small area and magnify it while retaining sharpness and depth, all without distortion. They must also be able to look at all sides of each piece, preferably without moving the piece. The best inspection tools must be able to aim the magnifying element and the lights at a highly targeted area to minimize the effect of shadows on the inspection process. This means the tool should ideally be able to view components on their horizontal as well as vertical axes. This can increase inspection throughput without reduction in efficiency and accuracy.

The Visual Inspection Stations from FSInspection.com, including the HDMag, X-Mag, VERSAMag, and PKMag, use smooth, continuous magnification that can resolve even the smallest defect. Our X-Mag and VERSAMag inspection stations have a flexible mounted camera that can rotate to inspect components from different angles along X-, Y, and X-axes without needing to reposition the part. All our Visual Inspection Stations all include lights that can be turned on or off, and aimed precisely to bring even the most subtle irregularity out of the darkness. Our Visual Inspection Stations are also ergonomically designed so operators do not have to hunch over a camera or push their eyes into awkward and uncomfortable eyepieces. Users can sit comfortably and view results on our large monitors, minimizing fatigue and reducing the chance of errors due to tiredness. The design also permits collaboration: Operators can share results on the screen, or can freeze and capture images to save to file.

Micro-machining has become an increasingly vital part of the manufacturing process, not only for medical applications, but also for aerospace, automotive, and other industries. Micro-machined parts can be of metal or plastic. The parts produced range from O-rings to screws to optical components such as lenses, plus the many other types of milled and molded components needed in the assembly process. Especially in the medical industry, which led the transition to miniaturized parts, the quality of the parts is critical to the effectiveness and safety of the final product.

As micro-machined parts are used to support more and more applications, the inspection process bears the burden of keeping in step. Operators must look for pits, burrs, and irregularities on the surface of metal and plastic components. They must look for uneven curvatures in lenses and other plastic parts. Inspectors must also be able to detect miniscule variations in measurements that would be within tolerance in a larger part. Accurate measurement of small increments has become an extremely important part of the quality control process for micro-machined components.

The very small size of these components means inspection tools must be able to focus on an extremely small area and magnify it while retaining sharpness and depth, all without distortion. The visual inspection station must be able to magnify both the part and the measuring device, keeping both in focus. The best inspection tools must also be able to aim lights at a highly targeted area to minimize the effect of shadows and glare from the surface of optical parts and molds. The use of magnifiers can increase throughput without reduction in efficiency and accuracy.

The visual inspection stations from FSInspection.com, including the HDMag, X-Mag, VERSAMag, and PKMag, use smooth, continuous magnification that can resolve even the smallest defect on both metal and plastic parts. They have the depth of field to place the component in context, keeping both the part and the measurement in focus. Our Visual Inspection Stations all include lights that can be turned on or off, and aimed precisely to bring even the most subtle irregularity out of the darkness. Our Visual Inspection Stations are also ergonomically designed so operators do not have to hunch over a camera or push their eyes into awkward and uncomfortable eyepieces. Users can sit comfortably and view results on our large monitors, minimizing fatigue and reducing the chance of errors due to tiredness. The design also permits collaboration: Operators can share results on the screen, or can freeze and capture images to save to file.

Macro-machined Components

Macro-machined parts are used in many industries, including transportation, aerospace, military, utilities, and construction. This group of components can include larger versions of those found as micro-machined parts, or specialized parts for larger systems. Macro-machined parts can be of metal or plastic. The list of milled and molded parts includes gears and splines, along with gear-cutting tools and other non-gear parts in a wide variety of shapes and sizes.

The parts are usually produced with multi-axis machining such as the newer five-axis machining centers. This has led to the ability to quickly produce more complex parts, including parts with curved holes and surfaces. The inspection process involves unique challenges deriving from these curvatures. In addition to typical inspection needs – identifying irregularities, pits, and burrs on surfaces – inspectors must also be able to identify errors in curvature and angle in both components and the molds that are used to generate them.

Visual inspection tools must be able to look at all sides of each piece, preferably without moving the piece. The best inspection tools will be able to move the magnifying element and the light to focus on each side in turn, while also following the line of any curves. This means the tool should ideally be able to view components on their horizontal as well as vertical axes. This can increase inspection throughput without reduction in efficiency and accuracy.

The visual inspection stations from FSInspection.com, including the HDMag, X-Mag, VERSAMag, and PKMag, use smooth, continuous magnification that can resolve many types of defects. For macro-machined components, we recommend the X-Mag and the VERSAMag Inspection Stations. Both these products have a flexible mounted camera that can rotate to inspect components from different angles along X-, Y, and X-axes without needing to reposition the part. Our Visual Inspection Stations all include lights that can be turned on or off, and aimed precisely to bring even the most subtle irregularity out of the darkness. The judicious use of lights can reduce glare from the surface of optical parts and molds Our Visual Inspection Stations are also ergonomically designed so operators do not have to hunch over a camera or push their eyes into awkward and uncomfortable eyepieces. Users can sit comfortably and view results on our large monitors, minimizing fatigue and reducing the chance of errors due to tiredness. The design also permits collaboration: Operators can share results on the screen, or can freeze and capture images to save to file.